Stretchable Cap and Manufacturing Method Thereof

ABSTRACT

A cap according to an exemplary embodiment of the present invention includes a head receiving portion stretchable along at least one direction and worn on the head, a sweat absorbing member disposed along a lower edge of the head receiving portion, absorbing sweat from the forehead, and is partly stretchable along the head circumferential direction of the head receiving portion, 
     The sweat absorbing member comprises a non-stretchability added portion at a location that corresponds to the forehead of a wearer and a material for adding non-stretchability to the non-stretchability added portion does not directly contact the forehead.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2010-0055625 filed in the Korean Intellectual Property Office on Jun. 11, 2010, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a stretchable cap and a manufacturing method thereof. More particularly, the present invention relates to a stretchable cap that people with a head size in a predetermined range can comfortably wear without adjusting the size while providing a deformation-free look like that of a fixed-size cap, and a manufacturing method thereof.

(b) Description of the Related Art

In general, a cap includes a head receiving portion formed to surround the head and a visor portion coupled to a lower end of the head receiving portion to block sunlight and the like.

In addition, a sweat absorbing member is further provided in a lower end of the head receiving portion to absorb sweat from the forehead of a wearer by contacting the forehead.

One of a free-sized cap and a one-size-fits-all type cap includes an elastic band provided along a lower circumferential direction of the head receiving portion to function as a sweat absorbing member while providing stretchability along the head circumferential direction.

However, while the free-sized cap has a merit of size adjustment with ease and revealing the head shape through the head receiving portion, it has a problem in that the shape of the cap is insufficiently stable due to stretchability of the head receiving portion and the sweat absorbing member.

Particularly, when a front stiffener is attached to a front portion of the head receiving portion, the front portion of the head receiving portion and the visor portion are not stretchable while the sweat absorbing member formed of an elastic band has stretchability, and accordingly the front portion of the head receiving portion, for example, a sewn area of the front portion of the head receiving portion and the visor portion may be crumpled, or a side portion of the head receiving portion may be deformed inwardly when the head receiving portion with the front stiffener, the visor and the sweat absorbing member are attached together by sewing.

In addition, because of the difference in the stretchability degree of the head receiving portion and that of the elastic band used as the sweat absorbing member, and tension of a sewing yarn, a side and a rear portion of the head receiving portion may be crumpled along the lower edge of the head receiving portion.

Such a problem cannot be easily solved by ironing, and even if the problem is temporally solved, the problem becomes worse if the cap is stored in a box or displayed in a store for a long period of time.

Then, a wearer may be visually unsatisfied with the deformed look of the cap, and the size written in the label and the substantial size of the cap may be different from each other, causing a reliability problem.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to provide a stretchable cap that can be comfortably worn without adjusting the size by people in a predetermined size range while providing a deformation-free look like a cap having a fixed size, and a manufacturing method thereof.

A cap according to an exemplary embodiment of the present invention includes a head receiving portion stretchable along at least one direction and worn on the head, a sweat absorbing member disposed along a lower edge of the head receiving portion and absorbing sweat from the forehead, and is partly stretchable along the head circumferential direction of the head receiving portion. The sweat absorbing member comprises a non-stretchability added portion at a location that corresponds to the forehead of a wearer and a material for adding non-stretchability to the sweat absorbing member to form the non-stretchability added portion does not directly contact the forehead.

A manufacturing method of a cap having a head receiving portion stretchable in at least one direction and worn on the head, and a sweat absorbing member disposed along a lower edge of the head receiving portion, absorbing sweat from the forehead, and having stretchablity along the head circumferential direction of the head receiving portion, includes forming a non-stretchability added portion at a part of the sweat absorbing member.

In the cap according to the exemplary embodiment of the present invention, the sweat absorbing member is wholly formed of a stretchable material and a portion corresponding to the forehead of a wearer is attached or coated with a non-stretchable material so that the portion can be closely sewn to the head receiving portion, and accordingly, the portion does not put pressure on the forehead of the wearer when the wearer wears the cap, and when the non-stretchable material is waterproof, sweat from the head or the forehead is not externally emitted to the head receiving portion so that the cap can be prevented from being stained.

In addition, in the cap according to the exemplary embodiment of the present invention, since a portion that does not directly contact the forehead among the portion of the sweat absorbing member, corresponding to the forehead, includes a non-stretchable material, the head receiving portion and the visor need not to be stretched when sewing the sweat absorbing member, the head receiving portion, and the visor together so that puckering of a lower portion of a front panel and deformation of double-stitched portions at both sides can be prevented, thereby providing consistency in sewing like a customized cap.

Further, the cap according to the exemplary embodiment of the present invention can prevent an excessive stretch of the lower end of the head receiving portion even though the head receiving portion is made of a stretchable material because the lower end of the head receiving portion is sewn using a non-stretchable yarn and a stretchable yarn, and can maintain a size range of the cap because a constant length of the lower end circumferential portion of the head receiving portion can be maintained.

According to the manufacturing method of a cap of the other exemplary embodiment of the present invention, a guide stitch formed at the lower end of the head receiving portion functions as a sewing guide when the sweat absorbing member or the visor is attached to the head receiving portion so that an additional inch tape is not required, and accordingly, product quality and productivity can be improved.

In addition, the cap according to the exemplary embodiment of the present invention does not use an inch tape because a guide stitch is formed at the lower end of the head receiving portion so that the sweat absorbing member can be prevented from being thickened or deformation of the lower end of the head receiving portion can be prevented.

In addition, an existing cap puts pressure on the forehead because a lower part of a front portion of an existing sweat absorbing member having stretchability is stretched to be integrally sewn with a head receiving portion so that the upper part of the front portion is inclined toward the forehead, thereby putting pressure on. However, the cap according to the exemplary embodiment of the present invention can minimize pressure on the forehead by forming a non-stretchability added portion at a location corresponding to the forehead, attaching the non-stretchability added portion to the head receiving member in a closely attached manner, and providing a space between the forehead of a wearer and the sweat absorbing member.

In addition, the cap according to the exemplary embodiment of the present invention can prevent loosening and curling of the lower end of the head receiving portion because the lower edge circumference is sewn using a non-stretchable yarn and a stretchable yarn before integrally sewing the lower end of the head receiving portion with the sweat absorbing member, and accordingly, a height change of the cap can be prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a cap according to an exemplary embodiment of the present invention,

FIG. 1B is a bottom view of the cap according to the exemplary embodiment of the present invention,

FIG. 2A is a cross-sectional view of FIG. 1A, taken along the line A-A,

FIG. 2B is a perspective view of a sweat absorbing member of the cap according to the exemplary embodiment of the present invention,

FIG. 3A is a side view of a head receiving portion of the cap according to the exemplary embodiment of the present invention,

FIG. 3B is a first stitch view of a lower edge of the head receiving portion of the cap according to the exemplary embodiment of the present invention,

FIG. 4A is a side view of a head receiving portion of a cap according to a modified exemplary embodiment of the present invention,

FIG. 4B shows a second stitch from the lower edge of the head receiving portion to a predetermined height of the cap according to the modified exemplary embodiment of the present invention, and

FIG. 5 is a flowchart of a cap manufacturing method according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

An exemplary embodiment of the present invention will now be described in further detail with reference to the accompanying drawings.

FIG. 1A is a perspective view of a cap according to an exemplary embodiment of the present invention, FIG. 1B is a bottom view of the cap according to the exemplary embodiment of the present invention, FIG. 2A is a cross-sectional view of FIG. 1A taken along the line A-A, and FIG. 2B is a perspective view of a sweat absorbing member of the cap according to the exemplary embodiment of the present invention.

Referring to FIG. 1A and FIG. 1B, a cap 100 according to an exemplary embodiment of the present invention includes a head receiving portion 101 worn on the head of a wearer, a visor portion 103 coupled to the head receiving portion 101 to block sunlight, and a stretchable sweat absorbing member 105 provided at an interior circumferential portion along the lower edge of the head receiving portion 101.

FIG. 1A and FIG. 1B illustrate one example among various types of exemplary embodiments, and thus the present invention is not limited to the cap shown in FIG. 1A and FIG. 1B. That is, the present invention can be applied to various types of caps, including a cap with a rim and a sun cap.

The head receiving portion 101 of a cap according to an exemplary embodiment of the present invention is formed of a plurality of pieces of cloth, including a piece of cloth at the front, a piece of cloth at the side, and a piece of cloth at the rear, and at least one of the plurality of pieces of cloth has stretchability along a head circumferential direction.

For this purpose, at least one of the pieces of cloth of the head receiving portion 101 is formed of a woven or knitted fabric, and the fabric may include an elastic yarn or a textured yarn.

In addition, the sweat absorbing member 105 may have stretchability along the head circumferential direction, and may use a woven or knitted fabric including an elastic yarn for the stretchability.

As shown in FIG. 2A, the sweat absorbing member 105 may be formed of a woven or knitted fabric having stretchability, and, as shown in FIG. 2B, the sweat absorbing member 105 may be formed of a cylindrically woven or knitted fabric such that the fabric layer can be double-layered. In addition, the sweat absorbing member 105 may be covered by a cover formed of a knitted or woven fabric made of a textured yarn, and the cover may include elastic yarn such as polyurethane or rubber yarns for improving stretchability.

The sweat absorbing member 105 made of a stretchable material includes a non-stretchability added portion 105 a at a location that corresponds to the forehead of a wearer in a manner that a non-stretchable material does not directly contact the forehead.

The non-stretchability added portion 105 a may be formed by sewing a non-stretchable fabric such as a waterproofed woven fabric, knitted fabric, or non-woven fabric on one side of the sweat absorbing member 105, by sewing or adhering using an adhesive a non-stretchable film at room temperature or a high temperature, or by attaching using an ultrasonic or high-frequency wave. Alternatively, the non-stretchability added portion 105 a may be formed by coating a material such as an adhesive or a binder.

The non-stretchability added portion 105 a has a waterproof function, the sweat absorbing member 105 is formed of a fabric having excellent absorptiveness for sweat absorption with ease, and the non-stretchability added portion 105 a is disposed at a location corresponding to the forehead in a manner that the non-stretchable material does not directly contact the forehead of the wearer so that a stain at the front portion of the head receiving portion due to sweat from the head or forehead can be prevented.

In addition, the sweat absorbing member 105 is formed with a stretchable material, but there is no need to stretch the sweat absorbing member 105 when sewing it because the non-stretchability added portion 105 a is formed at the front portion of the sweat absorbing member 105, so that less pressure is applied to the forehead of the wearer, and accordingly wearing comfort can be improved.

Table 1 shows comparison of crumpling at the front lower end and deformation at a double-stitched portion of lateral sides between 1000 caps according to the exemplary embodiment and 1000 existing caps according to a comparative example.

According to Table 1, the crumpling and the deformation of the cap according to the exemplary embodiment of the present invention are much less than those of the existing cap.

TABLE 1 Puckering at deformation in double-stitched Height and front portion portion at both sides size problem Exemplary 10 5 3 embodiment Comparative 150 120 120 example

This is because the front portion of the sweat absorbing member 105 including the non-stretchability added portion 105 a corresponds to a portion where the head receiving portion 101 and the visor portion 103 are sewn, and the sweat absorbing member 105 does not need to be stretched when being sewn in the stretchable cap according to the exemplary embodiment of the present invention.

On the contrary, in a conventional stretchable cap, the sweat absorbing member 105 needs to be stretched for being sewn on the head receiving portion 101, and front portion and both sides of the head receiving portion 101 may be crumpled or deformed due to restoring force.

That is, the cap according to the exemplary embodiment of the present invention does not need to have the sweat absorber or the front portion of the sweat absorbing member 105 stretched when sewing, and accordingly, productivity is increased and the cap can be constantly sewn like a tailored cap.

Meanwhile, in the conventional stretchable cap, the plurality of cloth pieces 101 a were connected and then sewn with the sweat absorbing member 105 such that the height of the cap was decreased due to loosening and curling of the lower edge portion of the head receiving portion 101.

Referring to FIG. 3A and FIG. 3B, the cap of which height change or loosening and curling of the lower edge of the head receiving portion 101 was prevented according to the exemplary embodiment of the present invention will now be described in detail.

FIG. 3A is a side view of the head receiving portion of the cap according to the exemplary embodiment of the present invention, and FIG. 3B shows a first stitch at the lower edge of the head receiving portion of the cap according to the exemplary embodiment of the present invention.

As shown in FIG. 3A and FIG. 3B, in the cap 100 according to the exemplary embodiment of the present invention, a first stitch 107 is formed along the lower edge of the head receiving portion 101 to solve the loosening and curling of the lower end of the head receiving portion 101 after the head receiving portion 101 is formed by connecting the cloth pieces 101 a with each other.

Particularly, when a front stiffener is attached to a front portion of the head receiving portion, the first stitch 107 may be formed only along the lower edge of a side portion and a rear portion of the head receiving portion 101. It is because that the loosening and curling of the lower end of the head receiving portion 101 is not occurred due to it.

At this time, the front portion may be provided with a guide stitch for guiding a location to which the visor portion is attached.

As shown in FIG. 3B, in the cap 100 according to the exemplary embodiment of the present invention, the first stitch 107 is formed by one upper line 107 a and two lower lines 107 b and 107 c in order to prevent loosening of the lower edge circumference of the head receiving portion 101.

In further detail, the upper line 107 a is formed with stitches distanced from each other by predetermined intervals at a predetermined height from the lower end of the head receiving portion 101. One lower line 107 b is sewn by weaving the upper line 107 a in a loop shape, and the other lower line 107 c is woven with the lower line 107 b in a loop shape at the lower end of the head receiving portion 101 to thereby prevent loosening of the lower end of the head receiving portion 101.

The upper line 107 a may be formed of a non-stretchable yarn and the lower lines 107 b and 107 c may be formed as a stretchable yarn.

The upper line 107 a formed of the non-stretchable yarn maintains a predetermined constant tension, and thus, even though the lower lines 107 b and 107 c are formed of stretchable yarns, an increase of sewing time due to deformation of the lines can be prevented and crumple or deformation due to stretching of both sides along the head circumferential portion of the cap can be prevented.

That is, since the upper line 107 a is formed of the non-stretchable yarn, the sewing speed can be increased while maintaining the head circumferential portion size of the head receiving portion 101 and the head receiving portion 101 can be prevented from being stretched too much or loosened by maintaining elasticity of the fabric along the head circumferential portion direction, and loosening of the lower end of the head receiving portion 101 can be easily prevented.

Here, the stretchable yarn may include a polyurethane yarn, a textured yarn, a false deformation yarn, and a stretch yarn.

Referring to FIG. 4A and FIG. 4B, a cap according to a modified exemplary embodiment of the present invention will now be described in detail. In the cap according to the present exemplary embodiment, a height change of the cap or loosening and curling of a lower edge of a head receiving portion 101 can be prevented.

FIG. 4A is a side view of a head receiving portion of the cap according to the present exemplary embodiment, and FIG. 4B shows a second stitch formed at a predetermined height from the lower edge of the head receiving portion of the cap according to the present exemplary embodiment.

As shown in FIG. 4A and FIG. 4B, a cap 100 according to the modified exemplary embodiment of the present invention may be formed with a second stitch 109 at an upper portion distanced from the lower edge of the head receiving portion 101 by a predetermined interval, in addition to a first stitch 107 formed for solving loosening and curling along the lower edge circumference of the head receiving portion 101, after forming the head receiving portion 101, by connecting a plurality of cloth pieces 101 a.

The second stitch 109 is distanced from the first stitch 107 by a predetermined interval, and an upper line 109 a is formed of stitches arranged in one line with predetermined intervals therebetween along the lower edge of the head receiving portion 101, as shown in FIG. 4A and FIG. 4B.

In further detail, the second stitch 109 is formed by weaving the upper line 109 a with a lower line 109 b in a loop shape, as shown in FIG. 4B. The lower line 109 is shown in the rear side of the cloth piece 101 of the head receiving portion 101.

The head receiving portion 101 formed along the lower edge of the second stitch 109 functions as a guide line to keep a referential margin to sew when attaching a visor portion 103 or a sweat absorbing member 105, and due to the second stitch 109, an inch tape (i.e., a measuring tape) that used to be disposed in the lower edge of the head receiving portion for keeping a margin for sewing before attaching the visor portion 103 or the sweat absorbing member 105 is not required.

That is, since the inch tape is not required, even if a non-stretchable material is added to one side of the sweat absorbing member 105 to form a non-stretchability added portion, the sweat absorbing member 105 is not thickened or deformed or does not impart pressure or stiffness to a wearer, and moreover, cap production efficiency can be improved.

In the cap 100 according to the present exemplary embodiment, as shown in FIG. 4B in detail, a first stitch 107 can be formed using one upper line 107 a and two lower lines 107 b and 107 c in order to prevent loosening along the lower edge circumference of the head receiving portion 101 as in the previously-stated exemplary embodiment, and therefore, no further description will be provided.

In the cap 100 according to the present exemplary embodiment, the upper line 109 a of the second stitch 109 may be formed of a non-stretchable yarn and the lower line 109 b may be formed of a stretchable yarn.

Thus, the upper line 109 a is formed of a non-stretchable yarn so that it may function as a guide line that can keep a margin for sewing when the visor portion 103 or the sweat absorbing member 105 is attached to the head receiving portion 101 by maintaining a predetermined constant tension.

In addition, although the head receiving portion 101 is formed with a stretchable material, the upper line 109 a formed of the non-stretchable yarn enables the head receiving portion 101 to maintain a constant circumference length by preventing an excessive stretch of the fabric. Furthermore, since an inch tape can be omitted, the production process can be simplified.

After the cap 100 is completed, the upper lines 107 a and 109 a maintain a predetermined tension along the lower edge of the head receiving portion 101 so that puckering can be prevented, and the sweat absorbing member 105 can be constantly sewn without loosening of the lower edge.

Hereinafter, a manufacturing method of a cap according to an exemplary embodiment of the present invention will be described in detail with reference to FIG. 5.

A manufacturing method of a cap and efficiency thereof according to an exemplary embodiment of the present invention will be briefly described in order to avoid redundancy in description.

In the manufacturing method of the exemplary embodiment of the present invention, a sweat absorbing member 105 is formed of a stretchable material, and a non-stretchability added portion 105 a is formed at a location of the sweat absorbing member 105, corresponding to the forehead.

The non-stretchability added portion 105 a may be attached by sewing one of a non-stretchable woven material, a non-stretchable knitted material, and a non-woven material, or by coating an adhesive or by heat-bonding a non-stretchable film with an ultrasonic or high-frequency wave.

The head receiving portion 101 forms by sewing a plurality of pieces of cloth 101 a with stretchability along at least one direction. In this case, a non stretchable yarn is used as an upper line 107 a along the lower edge of the head receiving portion 101 at predetermined intervals, and a first stitch 107 may be formed to prevent loosening of the lower edge.

A non-stretchable yarn at an upper portion at a predetermined distance from the first stitch 107 may be used as an upper line 109 a, and a second stitch 109 may be formed to form a series of guide lines. The second stitch 109 may be formed concurrently or successively with the first stitch 107.

As described, after forming the first and second stitches 107 and 109 at the lower edge of the head receiving portion 101, the sweat absorbing member 105 including the non-stretchability added portion 105 a can be integrally sewn without using an inch tape after coupling of the head receiving portion 101 and the visor portion 103.

The upper line 107 a forms with a series of stitches distanced from each other by predetermined intervals, and a first lower line 107 b and a second lower line 107 c are connected with the upper line 107 a in a loop shape such that the first stitch 107 is formed.

The upper line 109 a forms with a series of stitches distanced from each other by predetermined intervals, and a lower line 109 b connects between the upper lines 109 a such that the second stitch 109 is formed.

While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

DESCRIPTION OF SYMBOLS

-   -   100: cap     -   101: head receiving portion     -   103: visor portion     -   105: sweat absorbing member     -   105 a: non-stretchability added portion     -   107: first stitch     -   109: second stitch     -   107 a, 109 a: non-stretchable yarn     -   107 b, 107 c, 109 b: stretchable yarn 

1. A cap comprising a head receiving portion stretchable along at least one direction and worn on the head, a sweat absorbing member disposed along a lower edge of the head receiving portion, absorbing sweat from the forehead, and is stretchable along the head circumferential direction of the head receiving portion, wherein the sweat absorbing member comprises a non-stretchability added portion at a location that corresponds to the forehead of a wearer.
 2. The cap of claim 1, wherein the non-stretchability added portion has a waterproofing function.
 3. The cap of claim 2, wherein the non-stretchability added portion is formed by sewing at least one of a woven material, a knitted material, a non-woven material, and a film.
 4. The cap of claim 2, wherein the non-stretchability added portion is formed by coating an adhesive.
 5. The cap of claim 2, wherein the non-stretchability added portion is formed by thermally bonding a non-stretchable film with an ultrasonic wave or a high-frequency wave.
 6. The cap of claim 1, wherein the head receiving portion is provided at a lower edge thereof with a first stitch in which an upper line is formed of a non-stretchable yarn.
 7. The cap of claim 6, wherein the head receiving portion is further provided at an upper portion distanced from the first stitch by a predetermined interval with a second stitch of which an upper line is formed of a non-stretchable yarn.
 8. The cap of claim 6, wherein the first stitch has a upper line formed of stitches arranged in one line with predetermined intervals therebetween, and two lower lines connected to each other and the upper line in a loop shape.
 9. The cap of claim 7, wherein the second stitch includes a lower line weaving an upper line in a loop shape.
 10. The cap of claim 1, wherein the sweat absorbing member is formed with one type of stretchable band or fabric.
 11. A manufacturing method of a cap including a head receiving portion stretchable in at least one direction and worn on the head, and a sweat absorbing member disposed along a lower edge of the head receiving portion, absorbing sweat from the forehead, and having stretchablity along the head circumferential direction of the head receiving portion, comprising: forming a non-stretchability added portion at a part of the sweat absorbing member.
 12. The manufacturing method of claim 11, wherein the forming the non-stretchability added portion comprises partially attaching at least one of a non-stretchable woven material, a non-stretchable knitted material, a non-woven material, and a film to the sweat absorbing member, partially coating an adhesive to the sweat absorbing member, or partially heat-bonding the non-stretchable film to the sweat absorbing member using an ultrasonic wave or a high-frequency wave.
 13. The manufacturing method of claim 11, comprising: forming a head receiving portion by sewing a plurality of pieces of stretchable cloth with at least one of the non-stretchable woven material, the non-stretchable knitted material, the non-woven material, and the film; and forming a first stitch using a non-stretchable yarn as an upper line along the lower edge of the head receiving portion with a predetermined interval.
 14. The manufacturing method of claim 13, comprising forming a second stitch using a non-stretchable yarn as an upper line at a predetermined upper portion from the first stitch.
 15. The manufacturing method of claim 13, wherein the first stitch comprises an upper line formed of a series of stitches that are distanced from each other by predetermined intervals, and lower lines connected to the upper line and each other in a loop shape.
 16. The manufacturing method of claim 15, wherein the second stitch comprises an upper line formed of a series of stitches that are distanced from each other by predetermined intervals, and a lower line connected to the upper line in a loop shape.
 17. The manufacturing method of claim 16, comprising sewing the sweat absorbing member without an inch tape along the lower edge of the head receiving portion after forming the second stitch. 